Vertical tank oil-gas-water separation with calibration system

ABSTRACT

A multiphase flow calibration semi-closed loop system includes an oil-gas-water separation unit, a multiphase flow calibration unit, a single phase flow calibration section, a gas flow section, a flow data acquisition unit, and a programmable logic controller (PLC). The system is designed to have a two-step calibration process. In a first step, single phase water flow meters and single phase oil flow meters of the system are calibrated independently. In a second step, multiphase flow meters or multiphase water cut meters are calibrated using the pre-calibrated water flow meter, pre-calibrated oil flow meter, and the pre-calibrated gas flow meter. In doing so, the oil-gas-water separation unit, the multiphase flow calibration unit, the single phase flow calibration section, and the gas flow section communicate with the flow data acquisition unit providing real time data. Thus, the PLC connected to the flow data acquisition unit can perform the required calibration processes.

BACKGROUND Field of the Invention

The present disclosure relates to a multiphase flow meter calibrationsystem, method and apparatus. In particular, the system, method andapparatus of the present disclosure can be used for oil-gas-water flowmeter calibration and water cut meter calibration. In addition to beingused for three phase flow meter calibration, the system, method andapparatus of the present disclosure, which may be a semi-closed loopsystem, can also be independently used for single phase flow metercalibration and two phase flow meter calibration.

Description of the Related Art

In the petroleum industry, accurately measuring the fluid mixture flowrate in crude oil is a challenge. Due to the complex nature of crudeoil, measuring the fluid mixture flow rate of a multiphase fluid isparticularly difficult. With conventional two phase measurement methods,each phase of the fluid mixture, which is oil and water in thisinstance, need to be separated and such separation methods causeinterruptions in continuous industrial processes.

Generally, when measuring the water content in multiphase fluidmixtures, phase fraction measurement devices and phase velocitymeasurement devices are used. A Venturi meter is also used to measurethe flow rate of the fluid mixture, wherein measuring the flow rate ofthe fluid mixture requires having an accurate measurement of the fluidmixture density as an input parameter.

Within the oil and gas industry, an increased interest in studying theflow rate of multiphase fluid mixtures is clearly seen over the pastdecade. As a result, a number of different types of multiphase flowmeters (MPFM) were developed. However, these MPFM's are either expensiveor inaccurate. Thus, the desired results are not obtained or the processto obtain the desired results is considerably complex. Moreover, mostexisting systems are related to the calibration of oil-water flowmeters. Thus, a fluid mixture containing a gas component cannot becalibrated. See Aftab Ahmad and Luai M. Alhems. “Multiphase MeterCalibration System and Methods Thereof”, Patent ISSUED; Patent No U.S.Ser. No. 10/139,257 B2, 27 Nov. 2018; and Aftab Ahmad and Luai M.Alhems. “Calibration System Including Separation Vessel and Pipeline”,Patent Application Publication, Pub. No. US 2019/0049279 A1, 14 Feb.2019, each incorporated herein by reference in their entirety.

In view of the difficulties and drawbacks of the existing MPFM's, anobjective of the system of the present disclosure is to describe amultiphase flow meter calibration system. The system of the presentdisclosure is simple in design and accurately measures the flowparameters such as the fluid mixture flow rates, water content, and gasvolume fractions (GVFs). In contrast to existing calibration systems,the system of the present disclosure can calibrate flow meters thatmonitor a flow rate of a fluid mixture that contains a gas component.

Since multiphase flow meters are highly sophisticated devices thatinvolve huge investments, the accuracy of these devices are vital in theoil and gas industry. By utilizing the system of the present disclosure,multiphase flow meters and water cut meters can be accurately calibratedwith reduced operational complexity. The system of the presentdisclosure can also be used to calibrate single phase, two phase, andthree phase flow meters.

SUMMARY OF THE INVENTION

The system, method and apparatus of the present disclosure include amultiphase flow meter calibration system, method and apparatus thatinclude an oil-gas-water separation unit, a multiphase flow calibrationunit, a single phase flow calibration section, a gas flow section, aflow data acquisition unit, and a programmable logic controller (PLC).

The oil-gas-water separation unit, the multiphase flow calibration unit,the single phase flow calibration section, and the gas flow section arein fluid communication with each other through a piping system. The flowdata acquisition unit receives feedback from the oil-gas-waterseparation unit, the multiphase flow calibration unit, the single phaseflow calibration section, and the gas flow section.

Based upon the feedback received at the flow data acquisition unit, thePLC operates a plurality of valves, a plurality of pumps, and at leastone regulator to control the overall flow rate, and thus perform thecalibration process. In order to do so, the flow data acquisition unitis communicably coupled with the PLC.

During the calibration process, the system of the present disclosureutilizes a flow controller to control the variable flow pump flow ratesand gas flow control valves based upon the pre-defined water, oil, andgas volumetric flow rates.

The system of the present disclosure can be used for single phase, twophase, and three phase flow meter calibration processes.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1 is a piping and instrumentation diagram of the system of thepresent disclosure which is being used for multiphase flow metercalibration.

FIG. 2 is an illustration of the single phase flow calibration sectionused in the system of the present disclosure.

FIG. 3 is an illustration of the connections from the oil-gas-waterseparation unit, the multiphase flow calibration unit, the single phaseflow calibration section, the gas flow section to the flow controller,the flow data acquisition unit, and the programmable logic controller.

DETAILED DESCRIPTION

All illustrations of the drawings are for the purpose of describingselected embodiments of the present disclosure and are not intended tolimit the scope of the present disclosure or accompanying claims.

The present disclosure describes a multiphase (oil-gas-water) flow metercalibration system, method and apparatus (hereinafter referred to as“the system”). In particular, the system of the present disclosure canaccurately calibrate multiphase flow meters and multiphase water cutmeters. The system of the present disclosure can also be used forcalibration of single phase, two phase, and three phase flow meters.More specifically, the system of the present disclosure can be used tocalibrate single phase flow meters for gas, single phase flow meters foroil, single phase flow meters for water, two phase flow meters for gasand oil, two phase flow meters for oil and water, two phase flow metersfor water and gas, three phase flow meters for oil, gas, and water,water cut meters for two phase flows, and water cut meters for threephase flows. The system has a two-step calibration process for differentfluid flow rates, water-cuts and gas volume fractions (GVFs). In a firststep, the single-phase oil and water flow meters of the system arecalibrated separately using a single-phase flow loop section. A secondstep involves the calibration of the multi-phase flow meter or water-cutmeters using the three pre-calibrated system's single phase oil, water,and gas flow meters, wherein the gas flow meter is a factory calibratedgas flow meter.

As seen in FIG. 1 and FIG. 3, to fulfill the intended functionalities,the system of the present disclosure comprises an oil-gas-waterseparation unit 100, a multiphase flow calibration unit 200, a singlephase flow calibration section 333, a gas flow section 444, a flow dataacquisition unit 400, and a programmable logic controller (PLC) 500. Forthe flow rate measurements the flow meters are preferably one or more ofa magnetic flow meter, ultrasonic flow meter, and turbine flowmeter. Wepreferred turbine flow meters for the disclosed system The oil-gas-waterseparation unit 100, the multiphase flow calibration unit 200, which isused for testing multiphase flow meters or multiphase water cut meters,and the single phase flow calibration section 333 are in fluidcommunication with each other through a piping system 445.

A multiphase fluid inlet 410 is in fluid communication with theoil-gas-water separation unit 100 such that a fluid mixture can flowinto the oil-gas-water separation unit 100 through the multiphase fluidinlet 410. To draw a water phase from a water section 115 of theoil-gas-water separation unit 100, a single phase water outlet 117 is influid communication with the water section 115, preferably through avariable flow water pump 101, and a water flow meter 107. On the otherhand, to draw an oil phase from an oil section 116 of the oil-gas-waterseparation unit 100, a single phase oil outlet 118 is in fluidcommunication with the oil section 116, preferably through a variableflow oil pump 102, and an oil flow meter 108. Since the single phasewater outlet 117 and the single phase oil outlet 118 are independent toeach other, the water flow meter 107 and the oil flow meter 108 can beindependently calibrated. During multiphase flow calibration, an outputfrom the single phase water outlet 117 and an output from the singlephase oil outlet 118 are combined at a phase combination piping joint446. To do so, the single phase water outlet 117 and the single phaseoil outlet 118 are in fluid communication with the phase combinationpiping joint 446. To provide a gas phase of a fluid mixture, a gas flowoutlet 447 is in fluid communication with a pressurized gas tank 401through a gas pressure regulator 403 and a gas flow meter 406. Similarto the single phase water outlet 117 and the single phase oil outlet118, the gas flow outlet 447 is also in fluid communication with thephase combination piping joint 446. A downstream homogenizer 409, whichcomprises a homogenizer inlet 448 and a homogenizer outlet 449, is usedfor thorough mixing of the fluid mixture. When used for multiphaseflowmeter calibration, a piping outlet 450 of the phase combinationpiping joint 446 is in fluid communication with the homogenizer inlet448. After mixing, for multiphase flowmeter calibration, the homogenizeroutlet 449 is in fluid communication with an inlet 11 of the multiphasecalibration unit 200. The fluid mixture that passed through themultiphase calibration process is returned to the oil-gas-waterseparation unit 100 through an outlet 12 of the multiphase calibrationunit 200 which is in fluid communication with the oil-gas-waterseparation unit 100.

In particular, the multiphase flow calibration unit 200 is installedinto a multiphase flow loop for calibration of either a multiphase flowmeter or a water cut meter. The multiphase flow calibration unit 200 isa hollow cylinder made of stainless steel with coupling type of pipingjoints. The gas flow section 444, which controls the gas flow of amixture that is within the piping system 445, is operatively coupledwith the piping system 445 through the phase combination piping joint446 in between the oil-gas-water separation unit 100 and the multiphaseflow calibration unit 200. In order to monitor and record data relatedto a fluid mixture that is within the piping system 445, theoil-gas-water separation unit 100, the multiphase flow calibration unit200, the single phase flow calibration section 333, and the gas flowsection 444 are communicably coupled with the flow data acquisition unit400. In particular, the flow data acquisition unit 400 receives aplurality of feedback signals from the oil-gas-water separation unit100, the multiphase flow calibration unit 200, the single phase flowcalibration section 333, and the gas flow section 444 and transfers theplurality of feedback signals to the PLC 500 so that the PLC 500 cancontrol components that can be, but are not limited to, a plurality ofpumps, a plurality of valves, and at least one regulator. To do so, asseen in FIG. 3, the flow data acquisition unit 400 is communicablycoupled with the PLC 500.

In a preferred embodiment, the oil-gas-water separation unit 100 is acylindrical horizontal tank divided into the water section 115 and theoil section 116 by a fluid separation weir 110 which is positionedapproximately at ⅔^(rd) of the diameter/height of the cylindricalhorizontal tank. The inlet and outlet of the calibration unit ispreferably a coupling for connecting the flow meters to be calibrated.Preferably the oil-gas-water separation tank is oriented to lay on itsside such that the water phase is at the bottom and the oil phase passesover a vertical weir and into an oil section. In particular, the fluidseparation weir 110 is positioned perpendicular to a lateral wall,wherein the cylindrical horizontal tank is resting on the lateral walland the fluid separation weir 110 is positioned at a distance which isapproximately equivalent to ⅔^(rd) of the overall diameter/height of thecylindrical horizontal tank. When a multiphase fluid mixture is usedwith the system of the present disclosure, the fluid mixture returns tothe oil-gas-water separation unit 100 at the water section 115 duringthe calibration process and separates into distinct phases by movingthrough a semi-closed loop within the oil-gas-water separation unit 100.A volume of gas within the fluid mixture returning to the oil-gas-waterseparation unit 100 is released to the atmosphere through a gas bleedingopening in the water section 115. The gas bleeding opening can be influid communication with an in-line gas purifier for gas purificationpurposes. In a different embodiment, a condensation process can beperformed for the gas exiting the gas bleeding section. Condensationprocesses are especially suitable for the cleaning of low flow highlyconcentrated streams of exhaust gas. The entire waste gas stream iscooled below the dew point of the vapors contained therein so that thegasses can condense on the surface of the heat exchanger (partialcondensation). Theoretically, the achievable recovery rates depend onlyon the initial concentration, the purification temperature and the vaporpressure of the condensable at that temperature. In practice, however,flow velocities, temperature profiles, the geometry of the equipment,etc. play decisive roles, as effects such as mist formation (aerosols),uneven flow in the condensers and uncontrolled ice formation interferewith the process of condensation and prevent an equilibriumconcentration from being reached at the low temperatures.

Due to gravity, water remains at the water section 115, whereas the oil,which has a density that is smaller than a density of water, flows overthe weir to the oil section 116 of the oil-gas-water separation unit100. Numerically, the density of oil is within a range of 0.90-0.95g/cm³ preferably 0.91 grams/cubic centimeter (g/cm³)-0.93 g/cm³ betweena temperature range of 10 centigrade (° C.)-30° C., preferably 15°C.-25° C. On the other hand, the density of water is approximately 1.0g/cm³. However, in a different embodiment, the density of water can be1.02 g/cm³ or 1.03 g/cm′ based upon the salt concentration in the water.Separating oil and water by using gravity is known as gravity separationand is a continuous oil-water separation process. Gravity separation isused in a wide variety of industries, and can be most simplydifferentiated by the characteristics of the mixture to beseparated—principally that of ‘wet’ i.e.—a suspension versus ‘dry’-amixture of granular product. Often other methods are applied to make theseparation faster and more efficient, such as flocculation, coagulationand suction. The most notable advantages of the gravitational methodsare their cost effectiveness and in some cases excellent reduction.Gravity separation is an attractive unit operation as it generally haslow capital and operating costs, uses few if any chemicals that mightcause environmental concerns and the recent development of new equipmentenhances the range of separations possible. Preferably, an API separatoris used in the system of the present disclosure. The API separator is agravity separation device designed using Stokes' law principles thatdefine the rise velocity of oil droplets based on their density, sizeand water properties. The design of the separator is based on thespecific gravity difference between the oil and the wastewater becausethat difference is much smaller than the specific gravity differencebetween the suspended solids and water. Based on that design criterion,most of the suspended solids will settle to the bottom of the separatoras a sediment layer, the oil will rise to top of the separator, and thewastewater will be the middle layer between the oil on top and thesolids on the bottom. The API design standards, when correctly applied,make adjustments to the geometry, design and size of the separatorbeyond simple Stokes Law principles. This includes allowances for waterflow entrance and exit turbulence losses as well as other factors. APISpecification 421 requires a minimum length to width ratio of 5:1 andminimum depth-to-width ratio of 0.3:0.5.

To function with the variable flow water pump 101 and the water flowmeter 107, the system of the present disclosure further comprises afirst water gate valve 103, a second water gate valve 104, and a one waywater valve 112. The variable flow water pump 101, the first water gatevalve 103, the second water gate valve 104, and the one way water valve112 are used to calibrate the water flow meter 107. To do so, the watersection 115 of the oil-gas-water separation unit 100 is in fluidcommunication with the variable flow water pump 101 through the firstwater gate valve 103. In other words, a section of the piping system 445extending from the water section 115 connects to the variable flow waterpump 101 through the first water gate valve 103. A section of the pipingsystem 445 extending from the variable flow water pump 101 is in fluidcommunication with the one way water valve 112 through the water flowmeter 107 and the second gate valve.

To function with the variable flow oil pump 102 and the oil flow meter108, the system of the present disclosure further comprises a first oilgate valve 105, a second oil gate valve 106, and a one way oil valve111. The variable flow oil pump 102, the first oil gate valve 105, thesecond oil gate valve 106, and the one way oil valve 111 are used tocalibrate the oil flow meter 108. The oil section 116 of theoil-gas-water separation unit 100 is in fluid communication with thevariable flow oil pump 102 through the first oil gate valve 105. Inother words, a section of the piping system 445 extending from the oilsection 116 connects to the variable flow oil pump 102 through the firstoil gate valve 105. A section of the piping system 445 extending fromthe variable flow oil pump 102 is in fluid communication with the oneway oil valve 111 through the second oil gate valve 106.

The gas flow section 444 controls a gas volume of the multiphase fluidmixture used with the system of the present disclosure. To do so, inaddition to the pressurized gas tank 401, the gas pressure regulator403, and the gas flow meter 406, the gas flow section 444 comprises agas gate valve 402, at least one temperature sensor 404, at least onepressure sensor 405, a gas flow control valve 407, and a one way gasvalve 408. The pressurized gas tank 401, the gas gate valve 402, the gaspressure regulator 403, the gas flow meter 406, the gas flow controlvalve 407, and the one way gas valve 408 are in fluid communication witheach other so that the gas entering the piping system 445 of the presentdisclosure can be controlled as preferred. The at least one temperaturesensor 404 and the at least one pressure sensor 405 are operativelycoupled with a gas line extending from the pressurized gas tank 401.Thus, accurate feedback regarding the temperature and pressure of thegas entering the piping system 445 can be acquired.

The type of variable flow pump used as the variable flow water pump 101and the variable flow oil pump 102 can be, but are not limited to, apressure dependent calibrated valve type, a pressure independent flowlimiting valve type, and a pressure independent control (PIC) valvetype. Pressure dependent calibrated valve types, commonly referred to ascircuit setters are used for pre-set proportional system balancing.Circuit setters incorporate a ball valve and two pressure ports throughwhich the entering and exiting pressures can be measured to determinethe pressure drop across the valve. A calibrated plate makes it possibleto balance and set flow. Circuit setters are field adjustable and may bepreset prior to balancing. They are inexpensive and readily available,however getting them properly set up at system start-up can be requiretime and expertise, depending on the number of circuits. Beinginexpensive, being field adjustable, and potentially being preset priorto balancing are some of the advantages of the pressure dependentcalibrated valve type variable flow pumps. Requiring time and expertisefor balancing is one of the disadvantage related to pressure dependentcalibrated valve type variable flow pumps.

Pressure independent flow limiting valves have cartridges on the insidethat move back and forth in response to system pressure changes. Thismovement increases or decreases the size of the internal orifice. Whenthe entering pressure is low, the spring-loaded cartridge inside thevalve opens, and in doing so allows more flow to pass through the valvedespite the low pressure. As entering pressure increases, the pressureacts on the spring, compressing it and reducing the orifice size so thatflow is limited through the valve. In either case, flow is quicklystabilized despite system pressure fluctuations—as long as the pressuresare within the operating range of the specific valve. Maintainingconstant flow despite pressure fluctuations, being pre-balanced, andhaving field adjustable operating ranges are some of the advantages ofpressure independent flow limiting valve type variable flow pumps.Requiring additional pump head, which is the vertical distance that canbe pumped, is one of the disadvantage related to pressure independentflow limiting valve type variable flow pumps.

PIC valves combine the functionality of a balancing valve, control valveand a differential pressure regulator all into one valve body.Generally, the recommendation is to use a valve that maintains its fullstroke capability despite any preset maximum flow rate; therefore, thevalve maintains full authority under all load conditions. PIC valvesincorporate a spring loaded differential pressure regulator, whichconstantly adjusts and compensates for fluctuations in system pressure.This internal element responds to pressure changes by moving up or downto maintain a constant flow despite these fluctuations. That is the keybenefit of PIC valves—a change in differential pressure does not cause achange in flow. PIC valves do not merely limit flow; they keep flow at aspecific setting depending on the signal to the control valve. Thiseliminates underflows and overflows through the coil and ensures a muchmore consistent energy transfer. Improving system efficiency, loweringsystem energy cost, and providing stable flow are some of the advantagesof PIC valve type variable flow pumps, and the related cost is a notabledisadvantage of PIC valve type variable flow pumps.

The flow meter used as the water flow meter 107 and the oil flow meter108 can be, but is not limited to a differential pressure flow meters, apositive displacement flow meter, a velocity flow meter, a mass flowmeter, or an open channel flow meter. A differential pressure flow metermeasures the differential pressure across an orifice where flow isdirectly related to the square root of the differential pressureproduced. There are also primary and secondary elements in differentialflow meters. The primary element produces change in kinetic energy usingeither flow nozzle, pitot tube, orifice plate, or venturi flow meters.The secondary element measures the differential pressure and providesthe signal. Differential pressure meters represent around ⅕ of all flowmeters around the world. They are commonly used in the oil & gasindustry, along with heat, ventilation, and air conditioning (HVAC),beverage, water, pharma, mining, paper and chemical applications.

Positive displacement (PD) flow meters measure the volume filled withfluid, deliver it ahead and fill it again, which calculates the amountof fluid transferred. It measures actual flow of any fluid while allother types of flow meters measure some other parameter and convert thevalues into flowrate. In PD flow meters, output is directly related tothe volume passing through the flow meter. PD flow meters include pistonmeters, oval-gear meters, nutating disk meters, rotary vane type meters,etc.

Positive displacement flow meters are known for their accuracy. They arecommonly used in the transfer of oils and fluids, like gasoline,hydraulic fluids as well as in-home use for water and gas applications.

Velocity meters measure velocity of the stream to calculate thevolumetric flowrate. These are less sensitive when the Reynolds numberof fluid is higher than 10000. Velocity flow meters include turbine,paddlewheel, vortex shedding, electromagnetic and sonic/ultrasonic flowmeters.

Mass flow meters are more effective in mass related processes as theymeasure the force that results from the acceleration of mass. Morespecifically, the force is measured as the mass moving per unit of time,instead of the volume per unit of time. Mass flow meters includeCoriolis mass meters and thermal dispersion meters. Typical applicationsfor mass flow meters are tied to chemical processes. In addition to thechemical and gas industries, typical industries using mass metersinclude pharma, power, mining and wastewater.

Measurement of liquid in open channels include v-notch, weirs andflumes. These dam-like structures, or overflows, allow for a limited orconcentrated free-flow of liquids based on the unique shape and size ofthe structure. This type of flow meter allows for a reading of theflowrate to be calculated. Common applications of open channel metersinclude free flowing liquids like streams, rivers, irrigation channelsand sewer/wastewater systems.

The gate valve used in the first water gate valve 103, the second watergate valve 104, the first oil gate valve 105, the second oil gate valve106, and the gas gate valve 402 can be, but is not limited to, a solidwedge gate valve, a flexible wedge gate valve, a split wedge or paralleldisks gate valve, an outside stem and screw type, and non-rising stemgate valve or insider screw type gate valve. A gate valve is generallyused to completely shut off fluid flow or, in the fully open position,provide full flow in a pipeline. Thus, the gate valve is used either inthe fully closed or fully open positions. A gate valve includes a valvebody, seat and disc, a spindle, gland, and a wheel for operating thevalve. The seat and the gate together perform the function of shuttingoff the flow of fluid.

Solid wedge gate valve type is most common & widely used type because ofthe simplicity and strength. A gate valve with a solid wedge may beinstalled in any position, and is suitable for almost all fluids.However, these type of gate valves do not compensate for changes in seatalignment due to pipe loads or thermal expansion. So, this type of diskdesign is most susceptible to leakage. Solid wedge is subjected tothermal locking if used in high-temperature service, wherein thermallocking is a phenomenon in which wedge is stuck between the seats due tothe expansion of the metal. Solid-wedge gate valves are generally usedin moderate to lower pressure-temperature applications.

The flexible wedge is a one-piece solid disk with a cut around theperimeter. These cuts vary in size, shape, and depth. A shallow, narrowcut on wedge perimeter gives less flexibility but retains strength. Acast-in recess or deeper and wider cut on wedge perimeter gives moreflexibility but compromises the strength. This design improves seatalignment and offers better leak tightness. It also improves performancein situations where thermal binding is possible. Flexible wedges gatevalves are used in steam systems. Thermal expansion of steam linesometime causes distortion of valve bodies which may lead to thermalblinding. The flexible gate allows the gate to flex as the valve seatcompresses due to thermal expansion of steam pipeline and preventthermal blinding. The disadvantage of flexible gates is that line fluidtends to collect in the disk. However, the design of the flexible wedgemay result in corrosion and ultimately weaken the disk.

The split wedge disk type gate valve comprises of two solid pieces andholds together with the help of special mechanism. In case, one-half ofthe disk is out of alignment; the disk is free to adjust itself to theseating surface. The split disk can be in a wedge shape or a paralleldisk type. Parallel disks are spring loaded, so they are always incontact with seats and give bi-directional sealing. Split wedge issuitable for handling noncondensing gasses and liquids at normal andhigh temperature. Freedom of movement of the disk prevents thermalbinding even though the valve may have been closed when a line is cold.Therefore, when a line is heated by fluid and expanded it does notcreate thermal blinding.

In the outside stem and screw type, the stem will go up while openingthe valve and move down when the valve is closed. In an inside screwdesign, the threaded portion of the stem is in contact with the flowmedium and when valve is opened, a hand wheel rises with the stem.Whereas in the case of outside screw design, the only smooth portion isexposed to the flow medium and stem will rise above the hand wheel. Thistype of valve is also known as OS & Y valve, wherein OS & Y stands foroutside steam and York.

In the non-rising stem gate valve or insider screw type gate valve,which is also known as an insider screw valve, there is no upwardmovement of the stem in a non-rising stem type. The valve disk isthreaded internally. The disc travels along the stem like a nut when thestem is rotated. In this type of valve, stem threads are exposed to theflow medium. Therefore, this design is used where space is limited toallow linear stem movement, and the flow medium does not cause erosion,corrosion, or wear and tear to stem material.

The one way valve that is used in the one way water valve 112, the oneway oil valve 111, and the one way gas valve 408 can be, but is notlimited to, a duckbill valve, an umbrella valve, a mini valve ball, or across-slit valve. In general, a one way valve is a component used tocreate a unidirectional flow in a device. They are in fact elastomericsealing elements that allow forward flow and prevent backflow.

Duckbill valves are unique, one-piece, elastomeric components that actas backflow prevention devices or one-way valves or check valves. Theyhave elastomeric lips in the shape of a duckbill which prevent backflowand allow forward flow. The main advantage of duckbill valves over othertypes of one-way valves is that duckbill valves are self-contained i.e.the critical sealing function is an integral part of the one pieceelastomeric component as opposed to valves where a sealing element hasto engage with a smooth seat surface to form a seal. Therefore, duckbillvalves are easily incorporated and assembled into a wide variety ofdevices without the hassle or problems associated with the surfacefinish quality of mating seats and/or complex assembly processes.

The application of umbrella valves include vessel vent valves such asfor automotive fuel tanks, in- and outlet valves for piston- anddiaphragm pumps, one-way check valves in (disposable) breathing masks,and numerous other fluid control functions in medical devices, homeappliances, cars and toys. Umbrella valves are elastomeric valvecomponents that have a diaphragm shaped sealing disk or an umbrellashape. These elastomeric components are used as sealing elements inbackflow prevention devices or one-way valves or check valves, in ventvalves or pressure relief valves and in metering valves. When mounted ina seat, the convex diaphragm flattens out against the valve seat andabsorbs a certain amount of seat irregularities and creates a certainsealing force. The umbrella valve will allow forward flow once the headpressure creates enough force to lift the convex diaphragm from the seatand so it will allow flow at a predetermined pressure in one way andprevent back flow immediately in the opposite way. The main advantagecompared to other types of valves such as spring loaded disc valves isthat an umbrella valve uses the elastic material properties and thepreloaded convex shape to create the sealing force against the seat andthat it uses the central stem to hold the component in place so as toavoid the need for additional components such as a spring and the needfor a central or circumferential disc positioner(s). This simplifies thedesign of the assembly and makes the valve adaptable to minimal space,reduces the number of pieces in a valve, simplifies assembly and lastbut not least is very cost effective.

Mini valve balls are the simplest example of a check valve or one-wayvalve. When in use, a ball moves freely downstream of a flow orifice.Upon back flow the ball moves with the flow and closes the orifice andso blocks further back flow. This type of free shuttling valve will havethe lowest opening pressure but will require some initial back flow andthus leakage to close. Functionality can be improved with using a lightspring to keep the valve against the seat at zero pressure differential.With higher spring forces a pressure relief valve can also be created.

Cross-slit valves, which belong in the duckbill valve family, have thesame features and benefits as the duckbill valves. The main advantageover a regular duckbill valve is that the cross-slit valve has arelatively larger flow capacity. On the other hand, cross-slit valveshave a non-tortuous, straight line flow path as well and therefore canbe used in applications where instruments are pushed through the valve.Such as in a Trocar used for minimal invasive surgery procedures. Gas isprevented from venting out of the body cavity with either the instrumentinserted or withdrawn from the Trocar. One particular problem associatedwith using a backup seal is when various diameters of instruments areused in combination with a high back pressure. The larger the diameterrange and the larger the pressure the higher the insertion force.

The pressurized gas tank 401 used in the system of the presentdisclosure can be made of, but is not limited to, aluminum, steel,alloys, and composite materials. Mechanical strength, corrosionresistance, and impact resistance are critical factors in determiningwhich material is used. Carbon fiber composite cylinders can be verylight due to the high tensile strength of carbon fiber, but are moredifficult to manufacture.

The gas pressure regulator 403 used in the gas flow section 444 can be,but is not limited to, a line gas pressure regulator, a general purposegas pressure regulator, a high-purity gas pressure regulator, and aspecial service gas pressure regulator. Typically, line gas pressureregulators are point-of-use gas pressure regulators that servelow-pressure pipelines. These type of regulators can be used inconjunction with high-pressure cylinder regulators that limit the inletpressure to 250 pounds per square inch gauge (psig) to 400 psig. Generalpurpose gas regulators are designed for economy and longevity, and arerecommended for noncorrosive general plant, pilot plant, and maintenanceshop applications. High-purity gas pressure regulators are designed andconstructed to provide diffusion, resistance, and easy clean up. Inhigh-purity gas pressure regulators, inboard diffusion is minimized oreliminated by metal diaphragms and high-purity seats and seals. Specialservice gas pressure regulators are specifically constructed forspecialized applications including oxygen, acetylene and fluorineservice, high-pressure, ultra-high-pressure, and corrosion service.Additional custom gas pressure regulators are also available.

The at least one temperature sensor 404 used within the gas flow section444 can be, but is not limited to, a negative temperature coefficient(NTC) thermistor type, a resistance temperature detector (RTD) type, athermocouple type, or a semiconductor-based sensor type.

In a NTC thermistor type temperature sensor, a large, predictable, andprecise change is resistance correlated to variations in temperature isexhibited. A NTC thermistor provides a very high resistance at lowtemperatures. As temperature increases, the resistance drops quickly.Because an NTC thermistor experiences such a large change in resistanceper ° C., small changes in temperature are reflected very fast and withhigh accuracy (0.05 centigrade (° C.) to 1.5° C.). Because of itsexponential nature, the output of an NTC thermistor requireslinearization. The effective operating range is −50° C. to 250° C. forglass encapsulated thermistors or 150° C. for standard thermistors.

An RTD, also known as a resistance thermometer, measures temperature bycorrelating the resistance of the RTD element with temperature. An RTDcomprises of a film or, for greater accuracy, a wire wrapped around aceramic or glass core. The most accurate RTDs are made using platinum,but lower-cost RTDs can be made from nickel or copper that are not asstable or repeatable. Platinum RTDs offer a fairly linear output that ishighly accurate (0.1° C. to 1° C.) across −200° C. to 600° C. Whileproviding the greatest accuracy, RTDs also tend to be the most expensiveof temperature sensors.

A thermocouple temperature sensor type comprises of two wires ofdifferent metals connected at two points. The varying voltage betweenthese two points reflects proportional changes in temperature.Thermocouples are nonlinear, requiring conversion when used fortemperature control and compensation, typically accomplished using alookup table. Accuracy is low, from 0.5° C. to 5° C. However,thermocouple temperature sensor types operate across the widesttemperature range, from −200° C. to 1750° C.

A semiconductor-based temperature sensor is placed on integratedcircuits (ICs). Thus, if utilized with the system of the presentdisclosure, the semiconductor-based temperature sensor can be integratedinto an electrical circuit associated with the flow data acquisitionunit 400. These sensors are effectively two identical diodes withtemperature-sensitive voltage vs current characteristics that can beused to monitor changes in temperature. They offer a linear response buthave the lowest accuracy of the basic sensor types at 1° C. to 5° C.They also have the slowest responsiveness (5 s to 60 s) across thenarrowest temperature range (−70° C. to 150° C.).

The at least one pressure sensor 405 used within the gas flow section444 can be, but is not limited to, an aneroid barometer sensor, amanometer sensor, a bourdon tube pressure sensor, and a vacuum pressuresensor.

An aneroid barometer sensor is composed of a hollow metal casing thathas flexible surfaces on its top and bottom. Atmospheric pressurechanges cause the metal casing to change shape, with mechanical leversaugmenting the deformation in order to provide more noticeable results.The level of deformation can also be enhanced by manufacturing thesensor in a bellows design. The levers are usually attached to a pointerdial that translates pressurized deformation into scaled measurements orto a barograph that records pressure change over time. Aneroid barometersensors are compact and durable, employing no liquid in theiroperations. However, the mass of the pressure sensing elements limit thedevice's response rate, making it less effective for dynamic pressuresensing projects.

A manometer is a fluid pressure sensor that provides a relatively simpledesign structure and an accuracy level greater than that afforded bymost aneroid barometers. The manometer takes measurements by recordingthe effect of pressure on a column of liquid. The most common form ofmanometer is the U-shaped model in which pressure is applied to one sideof a tube, displacing liquid and causing a drop in fluid level at oneend and a correlating rise at the other. The pressure level is indicatedby the difference in height between the two ends of the tube, andmeasurement is taken according to a scale built into the device. Theprecision of a reading can be increased by tilting one of themanometer's legs. A fluid reservoir can also be attached to render theheight decreases in one of the legs insignificant. Manometers can beeffective as gauge sensors if one leg of the U-shaped tube vents intothe atmosphere, and they can function as differential sensors whenpressure is applied to both legs. However, they are only effectivewithin a specific pressure range and, like aneroid barometers, have aslow response rate that is inadequate for dynamic pressure sensing.

Although bourdon tube pressure sensors function according to the sameessential principles as aneroid barometers, bourdon tubes employ ahelical or C-shaped sensing element instead of a hollow capsule. One endof the bourdon tube is fixed into connection with the pressure, whilethe other end is closed. Each tube has an elliptical cross-section thatcauses the tube to straighten as more pressure is applied. Theinstrument will continue to straighten until fluid pressure is matchedby the elastic resistance of the tube. For this reason, different tubematerials are associated with different pressure ranges. A gear assemblyis attached to the closed end of the tube and moves a pointer along agraduated dial to provide readings. Bourdon tube devices are commonlyused as gauge pressure sensors and as differential sensors when twotubes are connected to a single pointer. Generally, the helical tube ismore compact and offers more reliable performance than the C-shapedsensing element.

Vacuum pressure is generally below atmospheric pressure levels, and canbe challenging to be detected through mechanical methods. Pirani sensorsare commonly used for measurements in the low vacuum range, and rely ona heated wire with electrical resistance correlating to temperature.When vacuum pressure increases, convection is reduced and wiretemperature rises. Electrical resistance rises proportionally and iscalibrated against pressure in order to provide an effective measurementof the vacuum.

Ion or cold cathode sensors are commonly used for higher vacuum rangeapplications. These instruments rely on a filament that generateselectron emissions. The electrons pass onto a grid where they maycollide with gas molecules, thereby causing them to be ionized. Acharged collection device attracts the charged ions, and the number ofions it accumulates directly corresponds to the amount of moleculeswithin the vacuum, thus providing an accurate reading of the vacuumpressure.

In a preferred embodiment of the system of the present disclosure, afactory calibrated gas flow meter can be utilized. The gas flow meter406 utilized in the system can be, but is not limited to, a laminardifferential pressure (DP) based flow meter, a thermal flow meter, aCoriolis flow meter, an ultrasonic flow meter, or a variable area flowmeter.

When considering the functionality, a laminar DP based flow meter usesthe pressure drop created within a laminar flow element to measure themass flow rate of a fluid. A laminar flow element converts turbulentflow into laminar flow by separating it into an array of thin, parallelchannels. The decrease in pressure, or pressure drop, across the channelis measured using a differential pressure sensor. Because the flow isnot turbulent, but laminar, the Poiseuille Equation can then be used torelate the pressure drop to the volumetric flow rate. The volumetricflow rate can also be converted to a mass flow rate using densitycorrection at a given temperature and pressure.

Thermal flow meters use heat to measure the flow rate of a fluid.Thermal flow meters traditionally work in one of two ways. The firsttype measures the current required to maintain a fixed temperatureacross a heated element. As the fluid flows, particles contact theelement and dissipate or carry away heat. As the flow rate increases,more current is required to keep the element at a fixed temperature, andthe current requirement is proportional to the mass flow rate. Thesecond thermal method involves measuring the temperature at two pointson either side of an element or ‘hot wire’. As the fluid flows over theelement it carries the heat downstream, increasing the temperature ofthe downstream temperature sensor and reducing the temperature of theupstream sensor. The change in temperature is related to the fluid'smass flow.

The Coriolis flow meter uses the Coriolis effect to measure the massflow of a fluid. The fluid travels through single or dual curved tubes.A vibration is applied to the tube(s). The Coriolis force acts on thefluid particles perpendicular to the vibration and the direction of theflow. While the tube is vibrating upward, the fluid flow in forces downon the tube. As the fluid flows out of the tube, it forces upward. Thiscreates torque, twisting the tube. The inverse process occurs when thetube is vibrating downward. These opposing forces cause the tube totwist, the amplitude of which is directly related to mass flow of thefluid through the tube.

Ultrasonic flow meters use sound waves to measure the flow rate of afluid. Doppler flow meters transmit ultrasonic sound waves into thefluid. These waves are reflected off particles and bubbles in the fluid.The frequency change between the transmitted wave and the received wavecan be used to measure the velocity of the fluid flow. Time of flightflow meters use the frequency change between transmitted and receivedsound waves to calculate the velocity of a flow.

Variable area flow meters, or rotameters, use a tube and float tomeasure flow. As the fluid flows through the tube, the float rises.Equilibrium will be reached when pressure and the buoyancy of the floatcounterbalance gravity. The float's height in the tube is then used toreference a flow rate on a calibrated measurement reference.

The gas flow control valve 407 can be, but is not limited to, adiaphragm valve, a ball valve, and a butterfly valve. Diaphragm valvescan be manual or automated. Automated diaphragm valves may usepneumatic, hydraulic or electric actuators along with accessories suchas solenoid valves, limit switches and positioners. In addition to thewell-known, two way shut off or throttling diaphragm valve, other typesinclude: Three way zero deadleg valve, sterile access port, block andbleed, valbow and tank bottom valve.

The ball valve's ease of operation, repair, and versatility has resultedin extensive industrial use, supporting pressures up to 1,000 bar (100MPa; 15,000 psi) and temperatures up to 752° F. (400° C.), depending ondesign and materials used. Sizes typically range from 0.2 to 48 inches(5.1 to 1,219.2 mm). Valve bodies are made of metal, plastic, or metalwith a ceramic; floating balls are often chrome plated for durability.One disadvantage of a ball valve is that they trap water in the centercavity while in the closed position. In the event of a freeze, the sidescan crack due to expansion of ice forming. Some means of insulation orheat tape in this situation will usually prevent damage. Another optionfor cold climates is the “freeze tolerant ball valve”. This style ofball valve incorporates a freeze plug in the side so in the event of afreeze up, the freeze plug ruptures (acts as a sacrificial disk), thusmaking for an easy repair. Now instead of replacing the whole valve,just screw in a new freeze plug.

Operation of a butterfly valve is similar to that of a ball valve, whichallows for quick shut off. Butterfly valves are generally favoredbecause they cost less than other valve designs, and are lighter weightso they need less support. The disc is positioned in the center of thepipe. A rod passes through the disc to an actuator on the outside of thevalve. Rotating the actuator turns the disc either parallel orperpendicular to the flow. Unlike a ball valve, the disc is alwayspresent within the flow, so it induces a pressure drop, even when open.

The downstream homogenizer 409 is used for thorough mixing of the fluidmixture containing a gas component. To do so, the downstream homogenizer409 is operatively coupled in between the multiphase flow calibrationunit 200 and both the oil-gas-water separation unit 100 and the gas flowsection 444. More specifically, an output from the water section 115, anoutput from the oil section 116, and an output from the gas flow section444 are transferred through the downstream homogenizer 409, atemperature sensor 113, a pressure sensor 114, and into the multiphaseflow calibration unit 200. The downstream homogenizer 409 used in thesystem of the present disclosure, is preferably a high downstreamhomogenizer that is usually used with liquids and similar materials.High pressure homogenizers force a liquid stream under high pressure,wherein the pressure can be up to 1500 bar/21,750 pounds per square inch(psi). High-pressure homogenizers consist of a tank to which highpressure is applied in order to force the liquid sample containedtherein through a valve or membrane with very narrow slits. This actcauses high shear, a large pressure drop, and cavitation, all of whichact to homogenize the sample. High-pressure homogenizers are mostcommonly used for creating emulsions and for cell lysis when relativelylarge volumes are being processed.

The single phase flow calibration section 333, which is used forcalibrating the water flow meter 107 and the oil flow meter 108,comprises a single phase calibration tank 300, a fluid level sensor 301,a drain gate valve 302, a single phase solenoid valve 303, a returnsingle phase solenoid valve 304, a return fluid pump 305, a fluid levelsighting glass 306, an air vent 308, and a removable lid 307. The draingate valve 302 and the removable lid 307 are used for cleaning andmaintaining the single phase calibration tank 300. To do so, the draingate valve 302 is in fluid communication with the single phasecalibration tank 300 and the removable lid 307 is removably attached tothe single phase calibration tank 300. The air vent 308 traversesthrough the removable lid 307. Therefore, when the removable lid 307 isattached to the single phase calibration tank 300, the air vent 308 canrelease the pressure from within the single phase calibration tank 300.The fluid level sighting glass 306, which extends outwards from thesingle phase calibration tank 300, is used to manually monitor a fluidlevel within the single phase calibration tank 300. In particular, thefluid level sighting glass 306 is used to view the fluid level sensor301 that gives feedback regarding the fluid level on a real-time basis.To do so, the fluid level sensor 301 is positioned within the singlephase calibration tank 300. As seen in FIG. 2, the fluid level sensor301 monitors a fluid level from a reference level to a maximum levelwithin the single phase calibration tank 300. Since the single phaseflow calibration section 333 is communicably coupled with the flow dataacquisition unit 400, the fluid level within the single phasecalibration tank 300 is automatically recorded by the flow dataacquisition unit 400. In order to perform the calibration processes, themultiphase flow calibration unit 200 is in fluid communication with thesingle phase calibration tank 300 through the single phase solenoidvalve 303. In order to match a reference level, the single phasecalibration tank 300 is in fluid communication with the return fluidpump 305 through the return single phase solenoid valve 304. Morespecifically, if a fluid level is above the reference level, the extravolume of water is pumped back to the water section 115 using the returnfluid pump 305. To do so, the return fluid pump 305 is in fluidcommunication with the water section 115 of the oil-gas-water separationunit 100.

The fluid level sensor 301 in a preferred embodiment of the system ofthe present disclosure can be, but is not limited to, a magneticallyactuated float sensor, a pneumatic level sensor, or a conductive levelsensor.

With magnetically actuated float sensors, switching occurs when apermanent magnet sealed inside a float rises or falls to the actuationlevel. With a mechanically actuated float, switching occurs as a resultof the movement of a float against a miniature (micro) switch. For bothmagnetic and mechanical float level sensors, chemical compatibility,temperature, specific gravity (density), buoyancy, and viscosity affectthe selection of the stem and the float. For example, larger floats maybe used with liquids with specific gravities as low as 0.5 while stillmaintaining buoyancy. The choice of float material is also influenced bytemperature-induced changes in specific gravity and viscosity—changesthat directly affect buoyancy.

Pneumatic level sensors are used where hazardous conditions exist, wherethere is no electric power or its use is restricted, or in applicationsinvolving heavy sludge or slurry. As the compression of a column of airagainst a diaphragm is used to actuate a switch, no process liquidcontacts the sensor's moving parts. These sensors are suitable for usewith highly viscous liquids such as grease, as well as water-based andcorrosive liquids. The use of pneumatic level sensors gives theadditional benefit of being a relatively low cost technique for pointlevel monitoring. A variation of this technique is the “bubbler”, whichcompresses air into a tube to the bottom of the tank, until the pressureincrease halts as the air pressure gets high enough to expel air bubblesfrom the bottom of the tube, overcoming the pressure there. Themeasurement of the stabilized air pressure indicates the pressure at thebottom of the tank, and, hence, the mass of fluid above.

Conductive level sensors are ideal for the point level detection of awide range of conductive liquids such as water, and is especially wellsuited for highly corrosive liquids such as caustic soda, hydrochloricacid, nitric acid, ferric chloride, and similar liquids. For thoseconductive liquids that are corrosive, the sensor's electrodes need tobe constructed from titanium, Hastelloy B or C, or 316 stainless steeland insulated with spacers, separators or holders of ceramic,polyethylene and Teflon-based materials. Depending on their design,multiple electrodes of differing lengths can be used with one holder.Since corrosive liquids become more aggressive as temperature andpressure increase, these extreme conditions need to be considered whenspecifying these sensors.

As described earlier, similar to the first water gate valve 103, thesecond water gate valve 104, the first oil gate valve 105, and thesecond oil gate valve 106, the gate valve used in the drain gate valve302 can be, but not limited to, a solid wedge gate valve, a flexiblewedge gate valve, a split wedge or parallel disks gate valve, an outsidestem and screw type, and non-rising stem gate valve or insider screwtype gate valve.

Solenoid valves control the flow rate of fluid and gases in systems,devices, and motors. These control valves that are uniquely distinctiveand have varying types evidently have carried out simple to complextasks without difficulty. These can be made particularly to matchspecialized needs and used to control liquids, gases, oils, electricity,among other mediums from low to high temperatures. These valves havebeen useful to various systems, control cylinders, motors, and otherindustrial valves acting on more than a few fundamental and multifacetedapplications. The type of solenoid valve used as the single phasesolenoid valve 303 and the return single phase solenoid valve 304 canbe, but are not limited to, a direct acting valve or a pilot-operatedvalve. In a direct acting valve, the force of a coil opens the valveport by taking the pin from the base of the valve. Direct actingsolenoid valve relies on the level of current in the coil to work. Thisvalve opens and closes notwithstanding the flow and pressure providedthat the available maximum pressure is not surpassed. In thepilot-operated valve, a pilot and main valve seats with orifices and amain valve diaphragm with restraining orifice. The top portion of thevalve is comprised of the pilot seat with corresponding orifice. Thepilot orifice is opened and closed by the plunger. The inlet linepressure causes to open and close the valve seal and goes through thepilot orifice. The pilot-operated valve always necessitates full powerboth to open and to be kept open.

The fluid pump used as the return fluid pump 305 can be, but is notlimited to, a piston pump, a circumferential-piston pump, a diaphragmpump, or a gear pump. The piston pump is a positive displacement pumpthat usually comprises of one or more pistons that draw fluid through aninlet check valve and expel the fluid through an outlet valve. Fluidvolume delivered depends on plunger diameter and stroke length; diametercannot be varied in a given pump, so stroke length is made adjustable.Most plunger pumps must be stopped for stroke adjustment, but a fewoffer the option of in-service adjustment. Outlet pressures delivered byplunger pumps are as high as 50,000 psi for some lab units. Maximumpressures for industrial pumps usually range from 5,000 to 30,000 psi.Maximum flow is as high as 26 gallons per minute (gpm) for traditionalplunger pumps and much higher for multi-piston units.

Circumferential-piston pumps use counter-rotating rotors driven byexternal timing gears. They are self-priming and have high suction liftcapability. With capacities up to 450 gpm, the pumps are often used forshear-sensitive fluids, or those with entrained particles or gases.

Diaphragm and bellows pumps are used when pump leakage or process-fluidcontamination cannot be tolerated. They offer the freedom from externalleakage of a peristaltic pump, yet permit higher pressures and easy flowadjustment. Diaphragm and bellows pumps generally tend to cost more thanperistaltic pumps for the same flow delivered. Generally, diaphragmpumps are built like a plunger unit, except that a bellows or diaphragmis fitted to the end of the plunger shaft. This configuration, whileproviding a positive seal, stresses the diaphragm because of unequalloading from the plunger. To equalize diaphragm loading, some pumps arebuilt so the plunger never contacts the diaphragm; instead, the plungerpressurizes a small volume of hydraulic fluid as it moves, and the fluiddisplaces the diaphragm. Diaphragm pumps of this type can deliver outletpressures to 5,000 psi.

Gear pumps, often used in fluid-power applications, perform equally aswell as fluid-handling pumps. The gears can be arranged as a pair ofsimilarly sized gears, as three stacked gears, as separated internalgears, or as gerotors which are positive displacement pumps.Displacement of gear pumps is fixed, and cannot be varied duringoperation.

To perform the calibration processes, the system of the presentdisclosure further comprises a multiphase solenoid valve 109. Themultiphase flow calibration unit 200 is in fluid communication with theoil-gas-water separation unit 100 through the multiphase solenoid valve109 creating a semi-closed loop system. Similar to the single phasesolenoid valve 303 and the return single phase solenoid valve 304, thetype of solenoid valve used as the multiphase solenoid valve 109 can be,but is not limited to, a direct acting valve or a pilot-operated valve.Direct acting solenoid valves are preferably used in the disclosedsystem.

As seen in FIG. 3, the system of the present disclosure furthercomprises a flow controller 600 that is used to control the variableflow water pump 101 and the variable flow oil pump 102 based upon thesignals received from the water flow meter 107 and the oil flow meter108. In other words, the flow controller 600 has the capability ofselecting a desired oil flow rate, a desired water flow rate, and adesired gas flow rate. To do so, the water flow meter 107, the oil flowmeter 108, and the gas flow meter 406 are communicably coupled with theflow controller 600, and the flow controller 600 is operatively coupledwith the variable flow water pump 101 the variable flow oil pump 102,and the gas flow control valve 407. The flow controller 600 in apreferred embodiment of the present disclosure can be, but is notlimited to, a mass flow controller (MFC) which is a device used tomeasure and control the flow of liquids and gases. A mass flowcontroller is designed and calibrated to control a specific type ofliquid or gas at a particular range of flow rates. The MFC can be givena set point from 0 to 100% of its full scale range but is typicallyoperated in the 10% to 90% of full scale where the best accuracy isachieved. The device will then control the rate of flow to the given setpoint. MFCs can be either analog or digital. A digital flow controlleris usually able to control more than one type of fluid whereas an analogcontroller is limited to the fluid for which it was calibrated.

As described earlier, the flow data acquisition unit 400 receives aplurality of feedback signals from the oil-gas-water separation unit100, the multiphase flow calibration unit 200, the single phase flowcalibration section 333, and the gas flow section 444 and transfers theplurality of feedback signals to the PLC 500 so that the PLC 500 cancontrol components that can be, but are not limited to, a plurality ofpumps, a plurality of valves, and at least one regulator. In a preferredembodiment of the present disclosure, the flow data acquisition unit 400is a microprocessor based flow data acquisition unit that monitors andprocesses real-time data. Preferably, the flow data acquisition unit 400is configured to display a plurality of parameters associated with thesystem of the present disclosure on a display screen. The dataacquisition system will also record and store the real-time data foroffline detailed data analysis.

In order to utilize the system of the present disclosure for calibrationpurposes, the oil-gas-water separation unit 100, the multiphase flowcalibration unit 200, and the single phase flow section are in fluidcommunication with each other through the piping system 445. Moreover,the gas flow section 444, which manages a gas component of a fluidmixture, is operatively coupled with the piping system 445 in betweenthe oil-gas-water separation unit 100 and the multiphase flowcalibration unit 200. The overall positioning of the gas flow section444 ensures that the system of the present disclosure can be used formultiphase flow meter calibration. The oil-gas-water separation unit100, the multiphase flow calibration unit 200, the single phase flowsection, and the gas flow section 444 are communicably coupled with theflow data acquisition unit 400 such that real time data can bemonitored, processed, and displayed when the flow data acquisition unit400 receives a plurality of feedback signals, wherein the plurality offeedback signals are generated from the oil-gas-water separation unit100, the multiphase flow calibration unit 200, the single phase flowcalibration section 333, and the gas flow section 444. Upon receivingthe plurality of feedback signals, the PLC 500, which is communicablycoupled with the flow data acquisition unit 400, proceeds to control aplurality of pumps, a plurality of valves, and at least one regulatorthat are associated with flow meter calibration.

When the system of the present disclosure is used to calibrate singlephase oil flow meters and single phase water flow meters, the water flowmeter 107 and the oil flow meter 108 are separately calibrated. In bothinstances, the single phase calibration tank 300 is used for monitoringpurposes, wherein the drain gate valve 302 is always kept in a closedposition unless the single phase calibration tank 300 requires cleaning.

When the water flow meter 107 is calibrated, the first water gate valve103 and the second water gate valve 104 that are in fluid communicationwith the water flow meter 107 are left in an open position. Since thewater flow meter 107 is calibrated independent of the oil flow meter108, wherein the oil flow meter 108 is positioned in parallel with thewater flow meter 107, the first oil gate valve 105 and the second oilgate valve 106 that are in fluid communication with the oil flow meter108 are kept in a closed position. The gas gate valve 402 that controlsthe flow of gas from the pressurized gas tank 401, is also kept in aclosed position. Moreover, the PLC 500 keeps the multiphase solenoidvalve 109, the single phase solenoid valve 303, and the return singlephase solenoid valve 304 in a closed position.

In order to calibrate the water flow meter 107, a desired flow rate forthe water flow meter 107 is set using the flow controller 600 which isin fluid communication with the water flow meter 107. More specifically,a calibration option corresponding to the water flow meter 107calibration is selected in the flow controller 600. In reference to FIG.3, the calibration option 001 is selected.

With the first water gate valve 103 and the second water gate valve 104in the open position, a position of the fluid level sensor 301 withinthe single phase calibration tank 300 is monitored. In particular, afeedback signal corresponding to a position of the fluid level sensor301, wherein the feedback signal is from the plurality of feedbacksignals generated within the system, is received from the fluid levelsensor 301. From the feedback signal that is received, the PLC 500determines if the multiphase solenoid valve 109 needs to be open orclosed. If the feedback signal corresponds to a position below areference level of the single phase calibration tank 300, the multiphasesolenoid valve 109 is opened and the variable flow water pump 101 isactivated. More specifically, the reference level corresponds to a leveldetermined by the flow controller 600. By opening the multiphasesolenoid valve 109 and activating the variable flow water pump 101, thevariable flow water pump 101 is allowed to draw a volume of water fromthe oil-gas-water separation unit 100 and transfer the volume of waterthrough the water flow meter 107. By drawing the volume of water, thefluid level sensor 301 can rise to match the reference level determinedby the flow controller 600 calibration option 001.

On the other hand, if the feedback signal corresponds to a positionabove the reference level of the single phase calibration tank 300, thePLC 500 opens the return single phase solenoid valve 304 and activatesthe return fluid pump 305. By doing so, the water within the singlephase calibration tank 300 is reduced and thus, the fluid level sensor301 lowers to a position below the reference level. When the fluid levelsensor 301 obtains a position below the reference level, the PLC 500closes the return single phase solenoid valve 304 and deactivates thereturn fluid pump 305.

When the position of the fluid level sensor 301 meets the referencelevel determined by the flow controller 600, the PLC 500 proceeds toclose the multiphase solenoid valve 109 and open the single phasesolenoid valve 303. By doing so, water is allowed to flow into thesingle phase calibration tank 300 and the fluid level sensor 301 iscontinuously monitored through the feedback signal received by the flowdata acquisition unit 400. Moreover, the flow data acquisition unit 400also records real time data from the fluid level sensor 301. Thecalibration is preferably carried out offline. The data collected fromthe calibration unit and the individual flow meters is used to obtainthe calibration constant of the flow meter to be calibrated. When thefeedback signal from the fluid level sensor 301 corresponds to a maximumfluid level position of the single phase calibration tank 300, the PLC500 proceeds to deactivate the variable flow water pump 101 and closethe single phase solenoid valve 303.

The process monitoring and recording is reiterated by setting differentwater flow rates for the water flow meter 107. In particular, theprocess is continued until a full range of water flow rates for thewater flow meter 107 is covered. When the data accumulation process iscomplete, the real time data recorded by the flow data acquisition unit400 at the single phase calibration tank 300 for different water flowrates are plotted against a set of water flow rate data obtained fromthe water flow meter 107 to calculate a calibration constant for thewater flow meter 107.

When the oil flow meter 108 is calibrated, the first oil gate valve 105and the second oil gate valve 106 that are in fluid communication withthe oil flow meter 108 are in an open position. Since the oil flow meter108 is calibrated independent of the water flow meter 107, wherein thewater flow meter 107 is positioned in parallel with the oil flow meter108, the first water gate valve 103 and the second water gate valve 104that are in fluid communication with the water flow meter 107 are keptin a closed position. The gas gate valve 402, which controls the flow ofgas from the pressurized gas tank 401, is also kept in a closedposition. Moreover, the PLC 500 keeps the multiphase solenoid valve 109,the single phase solenoid valve 303, and the return single phasesolenoid valve 304 in a closed position. In order to calibrate the oilflow meter 108, a desired flow rate for the oil flow meter 108 is setusing the flow controller 600 which is in fluid communication with theoil flow meter 108. More specifically, a calibration optioncorresponding to the oil flow meter 108 calibration is selected in theflow controller 600. In reference to FIG. 3, the calibration option 002is selected.

With the first oil gate valve 105 and the second oil gate valve 106 inthe open position, a position of the fluid level sensor 301 within thesingle phase calibration tank 300 is monitored. In particular, afeedback signal corresponding to a position of the fluid level sensor301, wherein the feedback signal is from the plurality of feedbacksignals generated within the system, is received from the fluid levelsensor 301. From the feedback signal that is received, the PLC 500determines if the multiphase solenoid valve 109 needs to be open orclosed. If the feedback signal corresponds to a position below areference level of the single phase calibration tank 300, the multiphasesolenoid valve 109 is opened and the variable flow oil pump 102 isactivated. More specifically, the reference level corresponds to a leveldetermined by the flow controller 600. By opening the multiphasesolenoid valve 109 and activating the variable flow oil pump 102, thevariable flow oil pump 102 can draw a volume of oil from theoil-gas-water separation unit 100 and transfer the volume of oil throughthe oil flow meter 108. By drawing the volume of oil, the fluid levelsensor 301 can rise to match the reference level determined by the flowcontroller 600. On the other hand, if the feedback signal corresponds toa position above the reference level of the single phase calibrationtank 300, the PLC 500 opens the return single phase solenoid valve 304and activates the return fluid pump 305. By doing so, the oil within thesingle phase calibration tank 300 is reduced and thus, the fluid levelsensor 301 lowers to a position below the reference level. When thefluid level sensor 301 obtains a position below the reference level, thePLC 500 closes the return single phase solenoid valve 304 anddeactivates the return fluid pump 305.

When the position of the fluid level sensor 301 meets the referencelevel determined by the flow controller 600, the PLC 500 proceeds toclose the multiphase solenoid valve 109 and open the single phasesolenoid valve 303. By doing so, oil is allowed to flow into the singlephase calibration tank 300 and the fluid level sensor 301 iscontinuously monitored through the feedback signal received by the flowdata acquisition unit 400. Moreover, the flow data acquisition unit 400also records real time data from the fluid level sensor 301. When thefeedback signal from the fluid level sensor 301 corresponds to a maximumfluid level position of the single phase calibration tank 300, the PLC500 proceeds to deactivate the variable flow oil pump 102 and close thesingle phase solenoid valve 303.

The process monitoring and recording is reiterated by setting differentoil flow rates for the oil flow meter 108. In particular, the process iscontinued until a full range of oil flow rates for the oil flow meter108 are covered. When the data accumulation process is complete, thereal time data recorded by the flow data acquisition unit 400 at thesingle phase calibration tank 300 for different oil flow rates areplotted against a set of oil flow rate data obtained from the oil flowmeter 108 to calculate a calibration constant for the oil flow meter108.

As described earlier, in a preferred embodiment of the presentdisclosure, a factory calibrated gas flow meter will be utilized. Thegas flow meter 406 utilized in the system can be, but is not limited to,a laminar differential pressure (DP) based flow meter, a thermal flowmeter, a Coriolis flow meter, an ultrasonic flow meter, or a variablearea flow meter.

The system of the present disclosure can be used for of single phase,two phase, and three phase flow meter calibration and water cut metercalibration. In particular, the system of the present disclosure can beused for calibrating single phase flow meters for gas, single phase flowmeters for oil, single phase flow meters for water, two phase flowmeters for gas and oil, two phase flow meters for oil and water, twophase flow meters for water and gas, three phase flow meters for oil,gas, and water, water cut meters for two phase flows, and water cutmeters for three phase flows.

The system of the present disclosure utilizes the water flow meter 107,the oil flow meter 108, and the gas flow meter 406 that are calibratedas described above along with the multiphase flow calibration unit 200and the downstream homogenizer 409 to calibrate multiphase flow metersor multiphase water cut meters.

When the system of the present disclosure is being used for calibratinga multiphase flow meter or a multiphase water meter, a first water gatevalve 103, a second water gate valve 104, a first oil gate valve 105,and a second oil gate valve 106 are in an open position. The first watergate valve 103 and the second water gate valve 104 are in fluidcommunication with the water flow meter 107, and the first oil gatevalve 105 and the second oil gate valve 106 are in fluid communicationwith the oil flow meter 108. Moreover, the multiphase solenoid valve 109is in an open position through the PLC 500. The single phase solenoidvalve 303 and the return single phase solenoid valve 304 remain in aclosed position during the calibration process.

In order to perform the multiphase flow meter calibration process, adesired fluid mixture flow rate for the multiphase flow meter is setusing the flow controller 600. By doing so, a volumetric flow for thewater, oil, and gas is managed by the flow controller 600. Based uponthe desired fluid mixture flow rate that corresponds to a calibrationsetting of the flow controller 600, the variable flow water pump 101draws a volume of water from the water section 115, and the variableflow oil pump 102 draws a volume of oil from the oil section 116. Thevolume of water and the volume of oil are then transferred through themultiphase flow calibration unit 200 using the piping system 445,wherein the multiphase flow meter is integrated into the multiphase flowcalibration unit 200.

In doing so, a fluid mixture pressure value is recorded at themultiphase flow calibration unit 200 and sent to the flow dataacquisition unit 400 from a pressure sensor 114 at the multiphase flowcalibration unit 200 as a feedback signal from the plurality of feedbacksignals. The flow data acquisition unit 400 proceeds to transfer thefeedback signal to the PLC 500 so that the PLC 500 can proceed to adjusta pipeline pressure. More specifically, the PLC 500 adjusts the pipelinepressure by controlling the gas pressure regulator 403 of the gas flowsection 444 while a gas flow control valve 407 of the gas flow section444 is in a closed position. The pipeline pressure is adjusted to bemarginally greater than the fluid mixture pressure value at themultiphase flow calibration unit 200 such that the one way gas valve 408of the gas flow section 444 can operate/open.

When the pipeline pressure is marginally greater than the fluid mixturepressure value, the PLC 500 instructs the flow controller 600 to openthe gas control valve to match a gas volumetric flow rate at themultiphase flow calibration unit 200, wherein the gas volumetric flowrate is determined from the desired fluid mixture flow rate. When thegas volumetric flow rate is achieved, the flow controller 600 sends aconclusion signal to the PLC 500, and the PLC 500 then proceeds torecord a set of real time data from the water flow meter 107, the oilflow meter 108, the gas flow meter 406, a temperature sensor 113 fromthe multiphase flow calibration unit 200, a pressure sensor 114 from themultiphase flow calibration unit 200, a temperature sensor 404 from thegas flow section 444, and a pressure sensor 405 from the gas flowsection 444. To do so, the flow data acquisition unit 400 is programmedto compute and display a set of real time data. The PLC 500 continues tosimultaneously communicate with the flow data acquisition unit 400 andthe flow controller 600 until the desired fluid mixture flow rate isachieved by the flow controller 600.

The process of monitoring and recording is reiterated by varying thedesired fluid mixture flow rates of the multiphase flow meter. Uponcompleting the reiteration process, in order to calculate a calibrationconstant, the set of real time data is plotted against a set of fluidmixture flow rate data from the flow controller 600. More specifically,the set of fluid mixture flow rate data corresponds to the multiphaseflow meter that is being calibrated. The process for calibrating themultiphase flow meter is replicated if a multiphase water meter is to becalibrated with the system of the present disclosure. The process forcalibrating the multiphase flow meter is also replicated whendetermining a gas volume fraction of a multiphase fluid mixture.

As described earlier, the system of the present disclosure can be usedfor calibrating a two phase flow meter. When an oil-gas flow meter isbeing calibrated, the first water gate valve 103 and the second watergate valve 104 that are in fluid communication with the water flow meter107 are in a closed position. On the other hand, the first oil gatevalve 105 and the second oil gate valve 106 that are in fluidcommunication with the oil flow meter 108, and the gas gate valve 402are in an open position. The multiphase solenoid valve 109 will be in anopen position by the PLC 500 whereas the single phase solenoid valve 303and the return single phase solenoid valve 304 will be in a closedposition. The gas flow control valve 407 will also be in a closedposition initially when the oil-gas flow meter is calibrated.

In order to perform the oil-gas flow meter calibration process, adesired fluid mixture flow rate is set using the flow controller 600such that a volumetric flow for oil and gas is managed by the flowcontroller 600. Based upon the desired fluid mixture flow rate set bythe flow controller 600, a volume of oil is drawn from the oil section116 using the variable flow oil pump 102. The volume of oil, whichcorresponds to a calibration setting of the flow controller 600, istransferred through the multiphase flow calibration unit 200 where theoil-gas flow meter is integrated. When the volume of oil is passingthrough the multiphase flow calibration unit 200, a pressure sensor atthe multiphase flow calibration unit 200 sends an oil pressure value tothe PLC 500. Upon analyzing the oil pressure value, the PLC 500 controlsthe gas pressure regulator 403 to set a pipeline gas pressure value withthe gas flow control valve 407 in a closed position. The pipeline gaspressure value is set to be marginally greater than the oil pressurevalue at the multiphase flow calibration unit 200 such that the one waygas valve 408 can be operated. If the pipeline gas pressure is obtained,the flow controller 600 sends a conclusion signal to the PLC 500 tomanage the gas flow control valve 407. As a result, the flow controller600 opens the gas flow control valve 407 until the desired fluid mixtureis obtained at the multiphase flow calibration unit 200. When thedesired fluid mixture is obtained, the flow data acquisition unit 400 isprogrammed to record a set of real time data using the gas flow meter406, the pressure sensor 405 associated with the gas flow section 444,the pressure sensor 114 of the multiphase flow calibration unit 200, thetemperature sensor 404 of the gas flow section 444, and the temperaturesensor 113 of the multiphase flow calibration unit 200. The PLC 500continues to simultaneously communicate with the flow data acquisitionunit 400 and the flow controller 600 until the desired fluid mixtureflow rate is achieved by the flow controller 600.

The process of monitoring and recording is reiterated by varying thedesired fluid mixture flow rates of the oil-gas flow meter. Uponcompleting the reiteration process, in order to calculate a calibrationconstant, the set of real time data obtained from the flow dataacquisition unit 400 is plotted against a set of fluid mixture flow ratedata obtained for the oil-gas flow meter at the multiphase flowcalibration unit 200. The process for calibrating the oil-gas flow meteris replicated if an oil-gas water meter is to be calibrated with thesystem of the present disclosure. The process for calibrating theoil-gas flow meter is also replicated when determining a gas volumefraction of an oil-gas fluid mixture.

When a water-gas flow meter is calibrated using the system of thepresent disclosure, a first oil gate valve 105 and a second oil gatevalve 106 that are in fluid communication with the oil flow meter 108are in a closed position. On the other hand, a first water gate valve103 and a second water gate valve 104 that are in fluid communicationwith the water flow meter 107 are in an open position along with a gasgate valve 402 of the gas flow section 444. The multiphase solenoidvalve 109 will be in an open position by the PLC 500 whereas the singlephase solenoid valve 303 and the return single phase solenoid valve 304will be in a closed position. The gas flow control valve 407 will alsobe in a closed position initially when the oil-gas flow meter iscalibrated.

In order to perform the gas-water flow meter calibration process, adesired fluid mixture flow rate is set using the flow controller 600such that a volumetric flow for gas and water are managed by the flowcontroller 600. Based upon the desired fluid mixture for the gas-waterflow meter, a volume water is drawn from the water section 115 using thevariable flow water pump 101. The volume of water, which corresponds toa calibration setting of the flow controller 600, is transferred throughthe multiphase flow calibration unit 200 where the gas-water flow meteris integrated.

When the flow controller 600 achieves a desired water flow rate, whichis derived from the desired fluid mixture flow rate, the flow controller600 sends a feedback signal to the PLC 500. A pressure sensor 114 at themultiphase flow calibration unit 200 also proceeds to send a waterpressure value to the PLC 500. Based upon the water pressure value, thePLC 500 proceeds to adjust the gas pressure regulator 403 to a pipelinegas pressure value while the gas flow control valve 407 is in a closedposition. The pipeline gas pressure value is set to be marginallygreater than the water pressure such that the one way gas valve 408 canbe operated. When the pipeline gas pressure is achieved, the PLC 500instructs the flow controller 600 to operate the gas flow control valve407 so that a desired volumetric gas flow rate is achieved at themultiphase flow calibration unit 200. Upon achieving the desiredvolumetric gas flow rate, the flow data acquisition unit 400 isprogrammed to record, compute, and display a set of real time data fromthe gas flow meter 406, the pressure sensor 114 at the multiphase flowcalibration unit 200, the pressure sensor 405 of the gas flow section444, the temperature sensor 113 at the multiphase flow calibration unit200, and the temperature sensor 404 of the gas flow section 444. The PLC500 continues to simultaneously communicate with the flow dataacquisition unit 400 and the flow controller 600 until the desired fluidmixture flow rate is achieved by the flow controller 600.

The process of monitoring and recording is reiterated by varying thedesired fluid mixture flow rates of the water-gas flow meter. Uponcompleting the reiteration process, in order to calculate a calibrationconstant, the set of real time data obtained from the flow dataacquisition unit 400 is plotted against a set of fluid mixture flow ratedata obtained for the water-gas flow meter at the multiphase flowcalibration unit 200. The process for calibrating the water-gas flowmeter is also replicated when determining a gas volume fraction of awater-gas fluid mixture.

When an oil-water flow meter is calibrated using the system of thepresent disclosure, a gas gate valve 402 of the gas flow section 444 isin a closed position. The first water gate valve 103 and the secondwater gate valve 104 that are in fluid communication with the water flowmeter 107 are in an open position. Moreover, the first oil gate valve105 and the second oil gate valve 106 that are in fluid communicationwith the oil flow meter 108 are in an open position. The multiphasesolenoid valve 109 is an open position using the PLC 500, whereas thesingle phase solenoid valve 303 and the return single phase solenoidvalve 304 are in a closed position.

In order to perform the oil-water flow meter calibration process, adesired fluid mixture flow rate is set using the flow controller 600such that a volumetric flow for oil and water is managed by the flowcontroller 600. Based upon the desired fluid mixture flow rate set bythe flow controller 600, a volume of oil is drawn from the oil section116 using the variable flow oil pump 102. Likewise, based upon thedesired fluid mixture flow rate set by the flow controller 600, a volumeof water is drawn from the water section 115 using the variable flow oilpump 102.

When the flow controller 600 achieves the desired oil and watervolumetric flow rates, the PLC 500 is notified such that the flow dataacquisition unit 400 can record a set of real time data from the waterflow meter 107, the oil flow meter 108, and the multiphase flowcalibration unit 200 where the oil-water flow meter is integrated. Theset of real time data obtained from the flow data acquisition unit 400is plotted against a set of fluid mixture flow rate data obtained forthe oil-water flow meter at the multiphase flow calibration unit 200,and the information derived from the set of real time data and the setof fluid mixture flow rate data are used for detailed analysis ofdifferent flow parameters. The process for calibrating the oil-waterflow meter is replicated when calibrating an oil-water water cut meteras well.

As described earlier, the system of the present disclosure can also beused for calibrating a single phase oil flow meter. Before starting thecalibration process for the single phase oil flow meter, the first watergate valve 103, the second water gate valve 104, and the gas gate valve402 are kept in a closed position. The first oil gate valve 105 and thesecond oil gate valve 106 are kept in an open position. The multiphasesolenoid valve 109 will be in an open position, whereas the single phasesolenoid valve 303 and the return single phase solenoid valve 304 willbe in a closed position. Moreover, the gas flow control valve 407 alsoremains in a closed position.

When calibrating the single phase oil flow meter, a desired oil flowrate is set for the single phase oil flow meter through the flowcontroller 600. In order to do so, a calibration option corresponding tothe desired oil flow rate is selected from the flow controller 600.Based upon the desired oil flow rate, the variable oil flow pump draws avolume of oil from the oil section 116, and the volume of oil istransferred through the multiphase flow calibration unit 200 where thesingle phase oil flow meter is integrated.

When the flow controller 600 achieves the desired oil flow rate, asignal is sent to the PLC 500 such that the PLC 500 instructs the flowdata acquisition unit 400 to record a set of real time data from the oilflow meter 108 and the multiphase flow calibration unit 200. The set ofreal time data is used for detailed analysis of the different flowparameters. The process of monitoring and recording the set of real timedata is reiterated for different oil flow rates. By doing so, the set ofreal time data from the flow data acquisition unit 400 can be plottedagainst the set of oil flow rate data at the multiphase flow calibrationunit 200 to determine a calibration constant.

The system of the present disclosure can also be used for calibrating asingle phase water flow meter. Before starting the calibration processfor the single phase water flow meter, the first oil gate valve 105, thesecond oil gate valve 106, and the gas gate valve 402 are in a closedposition. Moreover, the single phase solenoid valve 303 and the returnsingle phase solenoid valve 304 are in a closed position. The firstwater gate valve 103 and the second water gate valve 104, which are influid communication with the water flow meter 107, are in an openposition along with the multiphase solenoid valve 109 which is also inan open position via the PLC 500. Before the calibration process isinitiated, the gas flow control valve 407 also remains in a closedposition.

When calibrating the single phase water flow meter, a desired water flowrate is set for the single phase water flow meter through the flowcontroller 600. In order to do so, a calibration option corresponding tothe desired oil flow rate is selected from the flow controller 600.Based upon the desired water flow rate, the variable flow water pump101, draws a volume of water from a water section 115, and the volume ofwater is transferred through the multiphase flow calibration unit 200where the single phase water flow meter is integrated.

When the flow controller 600 achieves the desired water flow rate, asignal is sent to the PLC 500 such that the PLC 500 instructs the flowdata acquisition unit 400 to record a set of real time data from thewater flow meter 107 and the multiphase flow calibration unit 200. Theset of real time data is used for detailed analysis of the differentflow parameters. The process of monitoring and recording the set of realtime data is reiterated for different water flow rates. By doing, theset of real time data from the flow data acquisition unit 400 can beplotted against the set of oil flow rate data at the multiphase flowcalibration unit 200 to determine a calibration constant.

The system of the present disclosure can also be used for calibrating asingle phase gas flow meter. Before starting the calibration process forthe single phase gas flow meter, a first water gate valve 103, a secondwater gate valve 104, a first oil gate valve 105, and a second oil gatevalve 106 are set to a closed position. The gas gate valve 402 is in anopen position and the multiphase solenoid valve 109 is set to an openposition using the PLC 500.

When calibrating the single phase gas flow meter, a desired gas flowrate and a gas pressure value is set for the single phase water flowmeter through the flow controller 600. In order to do so, a calibrationoption corresponding to the desired gas flow rate is selected from theflow controller 600.

The pressure sensor at the multiphase flow calibration unit 200 sends asignal to the PLC 500 with the fluid mixture pressure value at themultiphase flow calibration unit 200. Based upon the fluid mixturepressure value, the PLC 500 adjusts the gas pressure regulator 403 to beset to a pipeline gas pressure. In doing so, the gas control valve iskept in a closed position. The pipeline gas pressure is selected to bemarginally greater than the fluid mixture pressure value at themultiphase flow calibration unit 200 such that the one way gas valve 408can be operated.

When the pipeline gas pressure is achieved, the PLC 500 instructs theflow controller 600 to operate the gas flow control valve 407. Inparticular, the flow control valve is left open until the desired gasflow rate is achieved at the multiphase flow calibration unit 200,wherein the single phase gas flow meter is integrated at the multiphaseflow calibration unit 200. The flow data acquisition unit 400 isprogrammed to monitor, record, and display a set of real time dataassociated with the gas volumetric flow rate at an inlet of themultiphase flow calibration unit 200 by using the gas flow meter 406,the pressure sensor of the gas flow section 444, the pressure sensor atthe multiphase flow calibration unit 200, the temperature sensor of thegas flow section 444, and the temperature sensor of the multiphase flowcalibration unit 200. The PLC 500 continues to simultaneouslycommunicate with the flow data acquisition unit 400 and the flowcontroller 600 until the desired flow rate at an inlet of the multiphaseflow calibration unit 200 is achieved by the flow controller 600.

When the flow controller 600 achieves the desired gas flow rate, asignal is sent to the PLC 500 such that the PLC 500 instructs the flowdata acquisition unit 400 to record a set of real time data from the gasflow meter 406, the pressure sensor of the gas flow section 444, thepressure sensor at the multiphase flow calibration unit 200, thetemperature sensor of the gas flow section 444, the temperature sensorof the multiphase flow calibration unit 200, and the multiphase flowcalibration unit 200 where the single phase gas flow meter isintegrated. The set of real time data is used for detailed analysis ofthe different flow parameters. The process of monitoring and recordingthe set of real time data is reiterated for different gas flow rates. Bydoing, the set of real time data from the data acquisition can beplotted against the set of gas flow rate data at the multiphase flowcalibration unit 200 to determine a calibration constant.

When determining the calibration constant of the water flow meter 107 inthe system of the present disclosure, a water volume flow rate, V_(w),for a fixed flow rate of the variable flow water pump 101 is obtainedfrom the following:

$\begin{matrix}{V_{w} = \frac{\Delta\; h_{w}A}{\Delta\; t}} & (1)\end{matrix}$

Where,

Δh=h _(2w) −h _(1w)

V_(w)=Water volume flow rate for a fixed pump flow rate, cubicmeters/second (m³/s);Δh_(w)=rise in water levels (in meters) in the calibration tank duringthe time interval Δt=(t₂−t₁) (secs);A=Cross-sectional area of the calibration square tank, m²;For different flow rates of the variable flow water pump 101, the actualvolume flow rate can be obtained from equation 1.The measured water volume flow rates obtained by varying the flow rateof the variable flow water pump 101 is compared with the data obtainedfrom the water flow meter 107. The calibration constant can bedetermined by plotting the water flow meter 107 data versus the measuredwater flow rates.

The calculation steps used for the calibration constant water flow meter107 of the system is replicated when calculating the calibrationconstant of the oil flow meter 108. The oil volume flow rate, V_(o), forthe variable flow oil pump 102 can be obtained by the following:

$\begin{matrix}{V_{o} = \frac{\Delta\; h_{o}A}{\Delta\; t}} & (2)\end{matrix}$

Where,

Δh _(o) =h _(2o) −h _(1o)

V_(o)=Oil volume flow rate for a fixed pump flow rate, m³/s;Δh_(o)=Rise in oil level (in meters) in the single phase calibrationtank 300 during the time interval Δt (t₂−t₁) (secs);A=Cross-sectional area of the single phase calibration tank 300, m²;

For different flow rates of the variable flow oil pump 102, the actualvolume flow rate can be obtained from equation 2.

The measured oil volume flow rates obtained by varying the flow rate ofthe variable flow oil pump 102 is compared with the data obtained fromthe oil flow meter 108. The calibration constant can be determined byplotting the oil flow meter 108 data versus the measured oil flow rates.

As described earlier, a factory calibrated gas flow meter will beutilized. The gas flow meter 406 utilized in the system can be, but isnot limited to, a laminar differential pressure (DP) based flow meter, athermal flow meter, a Coriolis flow meter, an ultrasonic flow meter, ora variable area flow meter.

When determining the multiphase flow meter or multiphase water cut metercalibration constant, a gas volume flow rate is measured at themultiphase flow calibration unit 200, wherein the multiphase flow meteror the multiphase water cut meter is integrated into the multiphase flowcalibration unit 200. The distance between the gas flow meter 406 andthe multiphase flow calibration unit 200 is the main reason formeasuring the gas volume flow rate at the multiphase flow calibrationunit 200. Due to the difference in pressure and temperature at the gasflow section 444 and an inlet of the multiphase flow calibration unit200, the gas volume flow rate at the multiphase flow calibration unit200 will vary depending on the conditions of the multiphase flowcalibration unit 200 inlet.

The gas volume flow rate at the multiphase flow calibration unit 200 iscomputed automatically by the flow data acquisition unit 400 from thereal time data acquired from the gas flow meter 406, temperature sensorof the multiphase flow calibration unit 200, temperature sensor of thegas flow section 444, the pressure sensor at the multiphase flowcalibration unit 200, and the pressure sensor at the gas flow section444.

The gas volume flow rate at an inlet of multiphase flow calibration unit200 is computed from the following equation using the constant mass flowrate principle:

$\begin{matrix}{V_{g} = {\frac{p_{m} \cdot T_{g}}{p_{g}T_{m}}V_{m}}} & (3)\end{matrix}$

Where,

V_(g)=Gas volume flow rate at the inlet of the multiphase flowcalibration unit 200, m³/s;V_(m)=Gas volume flow rate at the gas flow meter 406 location, m³/s;P_(g)=Absolute multiphase fluid mixture pressure at the inlet of themultiphase flow calibration unit 200, Pascal (Pa);P_(m)=Absolute gas pressure at the gas flow section 444, Pa;T_(g)=Multiphase fluid mixture temperature at the multiphase flowcalibration unit 200, Kelvin (K);T_(m)=Gas temperature at the gas flow section 444, K.

The system of the present disclosure can also be used for water cutmeasurement and calculating the calibration constant of the water cutmeter. The water cut, represented by λ, is the volume fraction of waterin a fluid mixture containing oil, gas, and water. For homogenous flow,and fixed flow rate flow pumps such as the variable flow water pump 101and the variable flow oil pump 102, the following equation can be usedfor the water cut:

$\begin{matrix}{\lambda = \frac{V_{w}}{V_{w} + V_{o} + V_{g}}} & (4)\end{matrix}$

Where,

λ=water-cut;V_(w)=water volume flow rate from water flow meter 107, m³/s;V_(o)=oil volume flow rate from oil flow meter 108, m³/s;V_(g)=calculated gas volume flow rate at the inlet of the multiphaseflow calibration unit 200, m³/s.The water cut, λ, for two phase flows such as oil-water and water-gas,using the appropriate volumetric flow rate terms can be obtained fromequation 4.

The data from the water flow meter 107 and the oil flow meter 108 thatare pre calibrated are used to calculate the water cuts for differentflow rates of the variable flow water pump 101 and the variable flow oilpump 102. The gas volume flow rate at the multiphase flow calibrationunit 200 is computed from the data obtained from the gas flow meter 406,the temperature sensor of the multiphase flow calibration unit 200, thetemperature sensor at the gas flow section 444, the pressure sensor atthe multiphase flow calibration unit 200, and the pressure sensor at thegas flow section 444 since the gas volumetric flow rate depends on thepressure and temperature in the flow loop pipeline.

The data obtained for the water cut meter, wherein the data was measuredby varying the flow rates of the variable flow water pump 101 and thevariable flow oil pump 102 and by injecting gas into the piping system445 at the defined liquid mixture for oil-water pressure, is comparedwith the data obtained from the water cut meter. Plotting the measuredwater cut meter data against the data from the water cut meter datahelps determine the calibration constant for the water cut meter.

When the system of the present disclosure is used to measure themultiphase fluid flow rate and find a calibration constant for themultiphase flow meter, the multiphase fluid flow rate is determineddirectly from the water flow meter 107 and the oil flow meter 108 thatare pre-calibrated and the gas volume flow rate which was calculated forthe multiphase flow calibration unit 200. The multiphase fluid volumeflow rate can be calculated from the following:

V _(m) =+V _(w) +V _(o) +V _(g)  (5)

Where,

V_(m)=Multiphase fluid mixture flow rate, m³/s;V_(w)=Water volume flow rate from water flow meter 107, m³/s;V_(o)=Oil volume flow rate from oil flow meter 108, m³/s;V_(g)=Calculated gas volume flow rate at the inlet of the multiphaseflow calibration unit 200, m³/s;The multiphase mixture fluid volume flow rate for two phase flows, suchas oil-water, water-gas, and gas-oil, using the appropriate volumetricflow rate terms can be obtained from equation 5.

The gas volume fraction (GVF), which is the ratio of gas volumetric flowrate to the total fluid mixture (oil-gas-water) flow rate, is obtainedfrom the following relation:

$\begin{matrix}{{GVF} = \frac{V_{g}}{V_{w} + V_{o} + V_{g}}} & (6)\end{matrix}$

The gas volume fraction (GVF) for two phase flows, such as oil-water,water-gas, and gas-oil, using the appropriate volumetric flow rateterms, can be obtained from equation 6.

The data from the water flow meter 107 that is pre-calibrated and thedata from the oil flow meter 108 that is pre-calibrated are useddirectly for different flow rates of the variable flow water pump 101and the variable flow oil pump 102. The gas volume flow rate at theinlet of the multiphase flow calibration unit 200 is computed from thedata obtained from the gas flow meter 406, temperature sensor of themultiphase flow calibration unit 200, temperature sensor of the gas flowsection 444, the pressure sensor of the multiphase flow calibration unit200, and the pressure sensor of the gas flow section 444. The flow dataacquisition unit 400 is programmed to obtain the gas volume flow rate atthe inlet of the multiphase flow calibration unit 200 by using themeasured data from the gas flow meter 406, temperature sensor of themultiphase flow calibration unit 200, temperature sensor of the gas flowsection 444, the pressure sensor of the multiphase flow calibration unit200, and the pressure sensor of the gas flow section 444.

The multiphase fluid mixture flow rate data that was obtained by varyingthe flow rate of the variable flow oil pump 102 and the variable flowwater pump 101 and by injecting different quantities of the gas iscompared with the data obtained from the multiphase flow meter. Thecalibration constant can be calculated by plotting the data from themultiphase flow meter versus the multiphase fluid flow rate data thatwas measured.

Terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention.

The headings (such as “Background” and “Summary”) and sub-headings usedherein are intended only for general organization of topics within thepresent invention, and are not intended to limit the disclosure of thepresent invention or any aspect thereof. In particular, subject matterdisclosed in the “Background” may include novel technology and may notconstitute a recitation of prior art. Subject matter disclosed in the“Summary” is not an exhaustive or complete disclosure of the entirescope of the technology or any embodiments thereof. Classification ordiscussion of a material within a section of this specification ashaving a particular utility is made for convenience, and no inferenceshould be drawn that the material must necessarily or solely function inaccordance with its classification herein when it is used in any givencomposition.

As used herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise.

It will be further understood that the terms “comprises” and/or“comprising,” when used in this specification, specify the presence ofstated features, steps, operations, elements, and/or components, but donot preclude the presence or addition of one or more other features,steps, operations, elements, components, and/or groups thereof.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items and may be abbreviated as“/”.

As used herein in the specification and claims, including as used in theexamples and unless otherwise expressly specified, all numbers may beread as if prefaced by the word “substantially”, “about” or“approximately,” even if the term does not expressly appear. The phrase“about” or “approximately” may be used when describing magnitude and/orposition to indicate that the value and/or position described is withina reasonable expected range of values and/or positions. For example, anumeric value may have a value that is +/−0.1% of the stated value (orrange of values), +/−1% of the stated value (or range of values), +/−2%of the stated value (or range of values), +/−5% of the stated value (orrange of values), +/−10% of the stated value (or range of values),+/−15% of the stated value (or range of values), +/−20% of the statedvalue (or range of values), etc. Any numerical range recited herein isintended to include all subranges subsumed therein.

Disclosure of values and ranges of values for specific parameters (suchas temperatures, molecular weights, weight percentages, etc.) are notexclusive of other values and ranges of values useful herein. It isenvisioned that two or more specific exemplified values for a givenparameter may define endpoints for a range of values that may be claimedfor the parameter. For example, if Parameter X is exemplified herein tohave value A and also exemplified to have value Z, it is envisioned thatparameter X may have a range of values from about A to about Z.Similarly, it is envisioned that disclosure of two or more ranges ofvalues for a parameter (whether such ranges are nested, overlapping ordistinct) subsume all possible combination of ranges for the value thatmight be claimed using endpoints of the disclosed ranges. For example,if parameter X is exemplified herein to have values in the range of 1-10it also describes subranges for Parameter X including 1-9, 1-8, 1-7,2-9, 2-8, 2-7, 3-9, 3-8, 3-7, 2-8, 3-7, 4-6, or 7-10, 8-10 or 9-10 asmere examples. A range encompasses its endpoints as well as valuesinside of an endpoint, for example, the range 0-5 includes 0, >0, 1, 2,3, 4, <5 and 5.

As used herein, the words “preferred” and “preferably” refer toembodiments of the technology that afford certain benefits, undercertain circumstances. However, other embodiments may also be preferred,under the same or other circumstances. Furthermore, the recitation ofone or more preferred embodiments does not imply that other embodimentsare not useful, and is not intended to exclude other embodiments fromthe scope of the technology.

As referred to herein, all compositional percentages are by weight ofthe total composition, unless otherwise specified. As used herein, theword “include,” and its variants, is intended to be non-limiting, suchthat recitation of items in a list is not to the exclusion of other likeitems that may also be useful in the materials, compositions, devices,and methods of this technology. Similarly, the terms “can” and “may” andtheir variants are intended to be non-limiting, such that recitationthat an embodiment can or may comprise certain elements or features doesnot exclude other embodiments of the present invention that do notcontain those elements or features.

Although the terms “first” and “second” may be used herein to describevarious features/elements (including steps), these features/elementsshould not be limited by these terms, unless the context indicatesotherwise. These terms may be used to distinguish one feature/elementfrom another feature/element. Thus, a first feature/element discussedbelow could be termed a second feature/element, and similarly, a secondfeature/element discussed below could be termed a first feature/elementwithout departing from the teachings of the present invention.

Spatially relative terms, such as “under”, “below”, “lower”, “over”,“upper”, “in front of” or “behind” and the like, may be used herein forease of description to describe one element or feature's relationship toanother element(s) or feature(s) as illustrated in the figures. It willbe understood that the spatially relative terms are intended toencompass different orientations of the device in use or operation inaddition to the orientation depicted in the figures. For example, if adevice in the figures is inverted, elements described as “under” or“beneath” other elements or features would then be oriented “over” theother elements or features. Thus, the exemplary term “under” canencompass both an orientation of over and under. The device may beotherwise oriented (rotated 90 degrees or at other orientations) and thespatially relative descriptors used herein interpreted accordingly.Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal”and the like are used herein for the purpose of explanation only unlessspecifically indicated otherwise.

When a feature or element is herein referred to as being “on” anotherfeature or element, it can be directly on the other feature or elementor intervening features and/or elements may also be present. Incontrast, when a feature or element is referred to as being “directlyon” another feature or element, there are no intervening features orelements present. It will also be understood that, when a feature orelement is referred to as being “connected”, “attached” or “coupled” toanother feature or element, it can be directly connected, attached orcoupled to the other feature or element or intervening features orelements may be present. In contrast, when a feature or element isreferred to as being “directly connected”, “directly attached” or“directly coupled” to another feature or element, there are nointervening features or elements present. Although described or shownwith respect to one embodiment, the features and elements so describedor shown can apply to other embodiments. It will also be appreciated bythose of skill in the art that references to a structure or feature thatis disposed “adjacent” another feature may have portions that overlap orunderlie the adjacent feature.

All publications and patent applications mentioned in this specificationare herein incorporated by reference in their entirety to the sameextent as if each individual publication or patent application wasspecifically and individually indicated to be incorporated by reference,especially referenced is disclosure appearing in the same sentence,paragraph, page or section of the specification in which theincorporation by reference appears.

The citation of references herein does not constitute an admission thatthose references are prior art or have any relevance to thepatentability of the technology disclosed herein. Any discussion of thecontent of references cited is intended merely to provide a generalsummary of assertions made by the authors of the references, and doesnot constitute an admission as to the accuracy of the content of suchreferences.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, theinvention may be practiced otherwise than as specifically describedherein.

1. A multiphase flow meter calibration system, comprising: anoil-gas-water separation unit, wherein the oil-gas-water separation unitis a cylindrical vertical tank comprising a fluid separation weir; amultiphase fluid inlet, wherein a multiphase fluid mixture flows intothe oil-gas-water separation unit through the multiphase fluid inlet; asingle phase water outlet, wherein the single phase water outlet is influid communication with a water section of the oil-gas-water separationunit through a variable flow water pump and a water flow meter; a singlephase oil outlet, wherein the single phase oil outlet is in fluidcommunication with an oil section of the oil-gas-water separation unitwith a variable flow oil pump and an oil flow meter; a phase combinationpiping joint, wherein the single phase water outlet and the single phaseoil outlet are in fluid communication with the phase combination pipingjoint; a gas flow outlet, wherein the gas flow outlet is in fluidcommunication with a pressurized gas tank through a gas pressureregulator and a gas flow meter; the gas flow outlet being in fluidcommunication with the phase combination piping joint; a downstreamhomogenizer, wherein the downstream homogenizer comprises a homogenizerinlet and a homogenizer outlet; a piping outlet of the phase combinationpiping joint being in fluid communication with the homogenizer inlet;the homogenizer outlet being in fluid communication with an inlet of amultiphase flow calibration unit; and the multiphase flow calibrationunit being in fluid communication with the oil-gas-water separationunit.
 2. (canceled)
 3. The multiphase flow meter calibration system asof claim 1 further comprising: a first oil gate valve; a second oil gatevalve; a one way oil valve; the oil section being in fluid communicationwith the variable flow oil pump through the first oil gate valve, andthe variable flow oil pump being in fluid communication with the one wayoil valve through the oil flow meter and the second oil gate valve. 4.The multiphase flow meter calibration system as of claim 1, wherein agas flow section comprises a gas gate valve, at least one temperaturesensor, at least one pressure sensor, a gas flow control valve, and aone way gas valve; the pressurized gas tank, the gas gate valve, the gaspressure regulator, the gas flow meter, the gas flow control valve, andthe one way gas valve being in fluid communication with each other; andthe at least one temperature sensor and the at least one pressure sensorbeing operatively coupled with a gas line extending from the pressurizedgas tank.
 5. The multiphase flow meter calibration system as of claim 1further comprising: a flow data acquisition unit; a programmable logiccontroller (PLC), wherein the PLC is communicably coupled with the flowdata acquisition unit; wherein the water flow meter, the oil flow meter,and the gas flow meter are communicably coupled with the flow dataacquisition unit; and wherein the PLC is operatively coupled with thevariable flow water pump, the variable flow oil pump, and the gaspressure regulator.
 6. The multiphase flow meter calibration system asof claim 5, wherein the data acquisition system is a microprocessorbased flow data acquisition unit.
 7. The multiphase flow metercalibration system as of claim 1 further comprising: a flow controller;the water flow meter and the oil flow meter being communicably coupledwith the flow controller; the gas flow meter being communicably coupledwith the flow controller; the flow controller being operatively coupledwith a variable flow water pump, and a variable flow oil pump; and theflow controller being operatively coupled with the gas flow controlvalve.
 8. The multiphase flow meter calibration system as of claim 1,wherein a single phase flow calibration section comprises a single phasecalibration tank, a fluid level sensor, a drain gate valve, a singlephase solenoid valve, a return single phase solenoid valve, a returnfluid pump, a fluid level sighting glass, an air vent, and a removablelid; the fluid level sensor being positioned within the single phasecalibration tank; the removable lid being removably attached to thesingle phase calibration tank; the fluid level sighting glass extendingoutwards from the single phase calibration tank; the air vent traversingthrough the removable lid; the multiphase flow calibration unit being influid communication with the single phase calibration tank through thesingle phase solenoid valve; the drain gate valve being in fluidcommunication with the single phase calibration tank; the single phasecalibration tank being in fluid communication with the return fluid pumpthrough the return single phase solenoid valve; and the return fluidpump being in fluid communication with a water section of theoil-gas-water separation unit.
 9. The multiphase flow meter calibrationsystem as of claim 1 further comprising: a multiphase solenoid valve;and the multiphase flow calibration unit being in fluid communicationwith the oil-gas-water separation unit through the multiphase solenoidvalve. 10-20. (canceled)